Laser Finishing Design Tool with 3-D Garment Preview

ABSTRACT

A tool allows a user to create new designs for apparel and preview these designs in three dimensions before manufacture. Software and lasers are used in finishing apparel to produce a desired wear pattern or other design. Based on a laser input file with a pattern, a laser will burn the pattern onto apparel. With the tool, the user will be able to create, make changes, and view images of a design, in real time, before burning by a laser. Input to the tool includes fabric template images, laser input files, and damage input. The tool allows adding of tinting and adjusting of intensity and bright point. The user can also move, rotate, scale, and warp the image input.

CROSS-REFERENCE TO RELATED APPLICATIONS

This patent application claims the benefit of U.S. patent application62/774,127 on Nov. 30, 2018. This application is incorporated byreference along with all other references cited in this application.

A portion of the disclosure of this patent document contains materialwhich is subject to copyright protection. The copyright owner has noobjection to the facsimile reproduction by anyone of the patent documentor the patent disclosure, as it appears in the U.S. Patent and TrademarkOffice patent file or records, but otherwise reserves all copyrightrights whatsoever.

BACKGROUND OF THE INVENTION

The present invention relates to apparel finishing and, morespecifically, the use of a laser in the finishing of garments,especially denim including jeans, shirts, shorts, jackets, vests, andskirts, to obtain a faded, distressed, washed, or worn finish orappearance.

In 1853, during the California Gold Rush, Levi Strauss, a 24-year-oldGerman immigrant, left New York for San Francisco with a small supply ofdry goods with the intention of opening a branch of his brother's NewYork dry goods business. Shortly after arriving in San Francisco, Mr.Strauss realized that the miners and prospectors (called the “fortyniners”) needed pants strong enough to last through the hard workconditions they endured. So, Mr. Strauss developed the now familiarjeans which he sold to the miners. The company he founded, Levi Strauss& Co., still sells jeans and is the most widely known jeans brand in theworld. Levi's is a trademark of Levi Strauss & Co. or LS&Co.

Though jeans at the time of the Gold Rush were used as work clothes,jeans have evolved to be fashionably worn everyday by men and women,showing up on billboards, television commercials, and fashion runways.Fashion is one of the largest consumer industries in the U.S. and aroundthe world. Jeans and related apparel are a significant segment of theindustry.

As fashion, people are concerned with the appearance of their jeans.Many people desire a faded or worn blue jeans look. In the past, jeansbecame faded or distressed through normal wash and wear. The apparelindustry recognized people's desire for the worn blue jeans look andbegan producing jeans and apparel with a variety of wear patterns. Thewear patterns have become part of the jeans style and fashion. Someexamples of wear patterns include combs or honeycombs, whiskers, stacks,and train tracks.

Despite the widespread success jeans have enjoyed, the process toproduce modern jeans with wear patterns takes processing time, hasrelatively high processing cost, and is resource intensive. A typicalprocess to produce jeans uses significant amounts of water, chemicals(e.g., bleaching or oxidizing agents), ozone, enzymes, and pumice stone.For example, it may take about 20 to 60 liters of water to finish eachpair of jeans.

Therefore, there is a need for an improved process for finishing jeansthat reduces environmental impact, processing time, and processingcosts, while maintaining the look and style of traditional finishingtechniques. There is a need for tool to creating and previewing patternson jeans before laser finishing.

BRIEF SUMMARY OF THE INVENTION

A tool allows a user to create new designs for apparel and preview thesedesigns in three dimensions before manufacture. Software and lasers areused in finishing apparel to produce a desired wear pattern or otherdesign. Based on a laser input file with a pattern, a laser will burnthe pattern onto apparel. With the tool, the user will be able tocreate, make changes, and view images of a design, in real time, beforeburning by a laser. Input to the tool includes fabric template images,laser input files, and damage input. The tool allows adding of tintingand adjusting of intensity and bright point. The user can also move,rotate, scale, and warp the image input.

In an implementation, a method includes providing a garment previewingtool that allows previewing on a computer screen of a jeans garmentcustomized by the user with a finishing pattern created using a laserinput file by a laser. The garment previewing tool includes: providingan option for the user to select a jeans garment base and upon theuser's selection, showing a first garment preview image on the computerscreen including a jeans base image for the selected garment base;providing an option for the user to select a wear pattern from a menu ofwear patterns, where each wear pattern is associated with a laser inputfile to be used by a laser to produce that wear pattern onto a jeansgarment; after the wear pattern is selected, showing a second garmentpreview image on the computer screen including the selected wear patternin combination with the jeans base image, where the second garmentpreview image replaces the first garment preview image; in the secondgarment preview image, allowing the user to select the wear pattern andmodify a sizing of the wear pattern relative to the jeans base image,where as the user makes changes, the modified sizing of the wear patternis displayed to the user in real time; in the second garment previewimage, allowing the user to select the wear pattern and modify aposition of the wear pattern relative to the jeans base image, where asthe user makes changes, the modified positioning of the wear pattern isdisplayed to the user in real time; and showing a third garment previewimage on the computer screen including the jeans base image and selectedwear pattern, with modified sizing or modified positioning, or acombination.

Further, a preview image generated by the garment previewing tool is athree-dimensional preview image of the jeans garment after a postlaserwash, simulated to have an appearance when worn by a person (withsimulated wrinkling or shadowing on the garment), and is rotatable inthree dimensions to be viewed from an angle selected by the user.

The method can further include: providing a target pair of jeanscorresponding to the jeans garment base selected by the user; and basedon laser input file associated with the third garment preview imageincluding the selected wear pattern with modified sizing or modifiedpositioning, or a combination, using a laser to create a finishingpattern on an outer surface of the target jeans.

In an implementation, a method includes providing a garment previewingtool that allows previewing on a computer screen of a garment customizedby the user with a finishing pattern created using a laser input file bya laser. The garment previewing tool includes: providing an option forthe user to select a garment base and upon the user's selection, showinga first garment preview image on the computer screen including a baseimage for the selected garment base; providing an option for the user toselect a pattern from a menu of patterns, where each pattern isassociated with a laser input file; after the pattern is selected,showing a second garment preview image on the computer screen includingthe selected pattern in combination with the base image, where thesecond garment preview image replaces the first garment preview image;in the second garment preview image, allowing the user to select thepattern and alter a sizing of the pattern relative to the base image,where as the user makes changes, the altered sizing of the pattern isdisplayed to the user in real time; in the second garment preview image,allowing the user to select the pattern and alter a position of thepattern relative to the base image, where as the user makes changes, thealtered positioning of the pattern is displayed to the user in realtime; and showing a third garment preview image on the computer screenincluding the base image and selected pattern, with altered sizing oraltered positioning, or a combination.

Further, a preview image generated by the garment previewing tool is athree-dimensional preview image of the jeans garment after a postlaserwash, simulated to have an appearance when worn by a person (withsimulated wrinkling or shadowing on the garment), and is rotatable inthree dimensions to be viewed from an angle selected by the user.

In an implementation, a method includes providing a garment previewingtool that allows previewing on a computer screen of a jeans garmentcustomized by the user with a finishing pattern created using a laserinput file by a laser. The garment previewing tool includes: providingan option for the user to select a jeans garment base and upon theuser's selection, showing a first garment preview image on the computerscreen including a jeans base image for the selected garment base;providing an option for the user to select a wear pattern from a menu ofwear patterns, where each wear pattern is associated with a laser inputfile to be used by a laser to produce that wear pattern onto a jeansgarment; after the wear pattern is selected, showing a second garmentpreview image on the computer screen including the selected wear patternin combination with the jeans base image, where the second garmentpreview image replaces the first garment preview image; in the secondgarment preview image, allowing the user to select the wear pattern andmodify a sizing of the wear pattern relative to the jeans base image,where as the user makes changes, the modified sizing of the wear patternis displayed to the user in real time; in the second garment previewimage, allowing the user to select the wear pattern and modify aposition of the wear pattern relative to the jeans base image, where asthe user makes changes, the modified positioning of the wear pattern isdisplayed to the user in real time; and showing a third garment previewimage on the computer screen including the jeans base image and selectedwear pattern, with modified sizing or modified positioning, or acombination.

Further, a preview image generated by the garment previewing tool is athree-dimensional preview image of the jeans garment after a postlaserwash, simulated to have an appearance when worn by a person (withsimulated wrinkling or shadowing on the garment), and is rotatable inthree dimensions to be viewed from an angle selected by the user.

The method can further include: providing a target pair of jeanscorresponding to the jeans garment base selected by the user; and basedon laser input file associated with the third garment preview imageincluding the selected wear pattern with modified sizing or modifiedpositioning, or a combination, using a laser to create a finishingpattern on an outer surface of the target jeans. The second garmentpreview image can be generated by: generating an adjusted base imagefrom the jean base image without the selected wear pattern; generating apattern mask based on the laser input file associated with the selectedwear pattern; for a pixel at a pixel location of the second previewimage, obtaining a first contribution for the pixel location of thesecond preview image by combining a first value for a pixelcorresponding to the pixel location for the pattern mask and a pixelcorresponding to the pixel location for the jeans base image; for thepixel at the pixel location of the second preview image, obtaining asecond contribution at the pixel location for the second preview imageby combining a second value for a pixel corresponding to the pixellocation for the pattern mask and a pixel corresponding to the pixellocation for the adjusted base image; combining the first contributionand second contribution to obtain a color value for a pixel at the pixellocation for the second preview image, and displaying the color valuefor the pixel at the pixel location in the second preview image.

In an implementation, a method includes generating a preview image on acomputer screen of a garment with a finishing pattern created using alaser input file by a laser. The generating the preview includes:providing a base image of the assembled garment without the finishingpattern; generating an adjusted base image from the base image of theassembled garment without the finishing pattern; generating a patternmask based on the laser input file; for a pixel at a pixel location ofthe preview image, obtaining a first contribution for the pixel locationof the preview image by combining a first value for a pixelcorresponding to the pixel location for the pattern mask and a pixelcorresponding to the pixel location for the base image; for the pixel atthe pixel location of the preview image, obtaining a second contributionat the pixel location for the preview image by combining a second valuefor a pixel corresponding to the pixel location for the pattern mask anda pixel corresponding to the pixel location for the adjusted base image;combining the first contribution and second contribution to obtain acolor value for a pixel at the pixel location for the preview image; anddisplaying the generated preview image on the computer screen includingthe color value for the pixel at the pixel location.

Further, a preview image generated is a three-dimensional preview imageof the jeans garment after a postlaser wash, simulated to have anappearance when worn by a person (with simulated wrinkling or shadowingon the garment), and is rotatable in three dimensions to be viewed froman angle selected by the user.

In an implementation, a method includes providing a garment previewingtool that allows previewing on a computer screen of a garment customizedby the user with a finishing pattern including a damage asset createdusing a damage asset laser input file by a laser, where the garmentpreviewing tool includes: providing an option for the user to select agarment base and upon the user's selection, showing a first garmentpreview image on the computer screen including a base image for theselected garment base; providing an option for the user to select adamage asset from a menu of damage assets, where each damage asset isassociated with a damage asset laser input file; after the damage assetis selected, showing a second garment preview image on the computerscreen including the selected damage asset in combination with the baseimage, where the second garment preview image replaces the first garmentpreview image; in the second garment preview image, allowing the user toselect the damage asset and alter a sizing of the damage asset relativeto the base image, where as the user makes changes, the altered sizingof the damage asset is displayed to the user in real time; in the secondgarment preview image, allowing the user to select the damage asset andalter a position of the damage asset relative to the base image, whereas the user makes changes, the altered positioning of the damage assetis displayed to the user in real time; and showing a third garmentpreview image on the computer screen including the base image andselected damage asset, with altered sizing or altered positioning, or acombination.

Further, a preview image generated is a three-dimensional preview imageof the jeans garment after a postlaser wash, simulated to have anappearance when worn by a person (with simulated wrinkling or shadowingon the garment), and is rotatable in three dimensions to be viewed froman angle selected by the user.

The damage asset can be created by: creating a damage shape in a blackcolor and storing in a damage asset laser input file, where the damageshape is associated with the damage asset; based on the damage assetlaser input file, using a laser to form the digital asset on a fabric;capturing an image of the damage asset on the fabric, and using theimage of the damage asset in the second garment preview image.

In an implementation, a method includes: creating a first damage shapein a black color; creating a second damage shape in a black color, wherethe second damage shape is different from the first damage shape;storing the first damage shape and second damage shape in a damage assetlaser input file; based on the damage asset laser input file, using alaser to form holes in a fabric based on the first and second damageshapes; washing the fabric with the holes; capturing a first image of afirst hole in the fabric that corresponds to the first shape; capturinga second image of a second hole in the fabric that corresponds to thesecond shape; using the first image as a first damage asset; using thesecond image as a second damage asset; providing a garment previewingtool that allows previewing on a computer screen of a garment customizedby the user with a finishing pattern including one or more damage assetsto be created using a laser; in the garment previewing tool, providingan option for the user to select a damage asset from a menu of damageassets including the first damage asset and the second damage asset;when the user selects the first damage asset, showing the first image aspart of a preview image of a garment being customized by the user; andwhen the user selects the second damage asset, showing the second imageas part of the preview image of a garment being customized by the user.

Further, a preview image generated is a three-dimensional preview imageof the jeans garment after a postlaser wash, simulated to have anappearance when worn by a person (with simulated wrinkling or shadowingon the garment), and is rotatable in three dimensions to be viewed froman angle selected by the user.

In an implementation, a method includes: assembling a garment made fromfabric panels of a woven first material including a warp includingindigo ring-dyed cotton yarn, where the fabric panels are sewn togetherusing thread; creating an image of a damage shape in a single color;storing the damage shape a damage asset laser file; based on the damageasset laser file, using a laser to form a hole in a second materialbased on the damage shape; washing the second material with the hole;capturing an image of the hole in the second material that correspondsto the damage shape; using the image of the hole in the second materialas a preview image of damage asset; allowing a user to select the damageasset using the preview image for use on the garment; using a laser tocreate the damage asset on an outer surface of the garment based on alaser input file including the damage shape, where based on the laserinput file, at a location specified for damage asset, the laser forms ahole in the first material in a shape corresponding the damage shape.Other objects, features, and advantages of the present invention willbecome apparent upon consideration of the following detailed descriptionand the accompanying drawings, in which like reference designationsrepresent like features throughout the figures.

Further, a preview image generated is a three-dimensional preview imageof the jeans garment after a postlaser wash, simulated to have anappearance when worn by a person (with simulated wrinkling or shadowingon the garment), and is rotatable in three dimensions to be viewed froman angle selected by the user.

Other objects, features, and advantages of the present invention willbecome apparent upon consideration of the following detailed descriptionand the accompanying drawings, in which like reference designationsrepresent like features throughout the figures.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 shows a block diagram of a system for creating, designing,producing apparel products with laser finishing.

FIG. 2 shows a flow for a finishing technique that includes the use of alaser.

FIG. 3 shows a weave pattern for a denim fabric.

FIGS. 4-7 show how the laser alters the color of ring-dyed yarn.

FIG. 8 shows a flow for finishing in two finishing steps and using basetemplates.

FIG. 9 shows multiple base templates and multiple resulting finishedproducts from each of these templates.

FIG. 10 shows a distributed computer network.

FIG. 11 shows a computer system that can be used in laser finishing.

FIG. 12 shows a system block diagram of the computer system.

FIGS. 13-14 show examples of mobile devices.

FIG. 15 shows a system block diagram of a mobile device.

FIG. 16 shows a block diagram of a system for creating, designing,producing apparel products with laser finishing.

FIG. 17 shows a block diagram of a specific implementation of a previewtool.

FIG. 18 shows a block diagram of a brief tool.

FIG. 19 shows a technique of generating a preview of a finished imageusing a brief tool.

FIG. 20 shows a laser pattern mask that is created from a laser inputfile.

FIG. 21 shows a base image hue saturation lightness adjustment (HSL)layer that is created from the base image.

FIG. 22 shows a technique of creating a masked solid color adjustmentlayer.

FIGS. 23-24 shows examples of two different adjustments for brightpoint.

FIG. 25 shows adjustment of intensity.

FIG. 26 shows an array of images showing the effects of adjustments inbright point and intensity.

FIG. 27 shows a block diagram of a system of generating a preview of alaser-finishing pattern on a garment, such as jeans.

FIG. 28 shows an overall flow for creating a three-dimensional previewfor an apparel product, such as a pair of jeans.

FIGS. 29A-29F show photographs of cutting a garment into pieces.

FIG. 30 shows a system for taking photographs of the garment pieces.

FIGS. 31A-31K show photographs of cut garment pieces and correspondingextracted neutral digital pattern pieces.

FIGS. 32A-32C show extracted shadow neutral pattern pieces. FIG. 32Dshows a shadow neutral texture created using the extracted shadowneutral pattern pieces and a color layer.

FIG. 33A shows a created shadow neutral texture. FIG. 33B shows a frontview of a three-dimensional model, which the shadow neutral texture willbe applied or mapped to.

FIG. 33C shows a result of mapping the shadow neutral texture to thethree-dimensional model. FIG. 33D shows a back or rear view of thethree-dimensional model, which the shadow neutral texture will beapplied or mapped to. FIG. 33E shows a result of mapping the shadowneutral texture to the three-dimensional model.

FIG. 34A shows an example of a simulated light source positioned to aright of and above the garment. FIG. 34B shows an example of a simulatedlight source positioned directly above the garment. FIG. 34C shows anexample of a simulated light source positioned to a left of and abovethe garment.

FIGS. 35A-35E show how a single three-dimensional model can be used withmultiple shadow neutral texture to generate a multiple preview images.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 shows a process flow 101 for manufacturing apparel such as jeans,where garments are finished using a laser. The fabric or material forvarious apparel including jeans is made from natural or synthetic fibers106, or a combination of these. A fabric mill takes fibers and processes109 these fibers to produce a laser-sensitive finished fabric 112, whichhas enhanced response characteristics for laser finishing.

Some examples of natural fibers include cotton, flax, hemp, sisal, jute,kenaf, and coconut; fibers from animal sources include silk, wool,cashmere, and mohair. Some examples of synthetic fibers includepolyester, nylon, spandex or elastane, and other polymers. Some examplesof semisynthetic fibers include rayon, viscose, modal, and lyocell,which are made from a regenerated cellulose fiber. A fabric can be anatural fiber alone (e.g., cotton), a synthetic fiber alone (e.g.,polyester alone), a blend of natural and synthetic fibers (e.g., cottonand polyester blend, or cotton and spandex), or a blend of natural andsemisynthetic fibers, or any combination of these or other fibers.

For jeans, the fabric is typically a denim, which is a sturdy cottonwarp-faced textile in which a weft passes under two or more warpthreads. This twill weaving produces a diagonal ribbing. The yarns(e.g., warp yarns) are dyed using an indigo or blue dye, which ischaracteristic of blue jeans.

Although this patent describes the apparel processing and finishing withrespect to jeans, the invention is not limited jeans or denim products,such as shirts, shorts, jackets, vests, and skirts. The techniques andapproaches described are applicable to other apparel and products,including nondenim products and products made from knit materials. Someexamples include T-shirts, sweaters, coats, sweatshirts (e.g., hoodies),casual wear, athletic wear, outerwear, dresses, evening wear, sleepwear,loungewear, underwear, socks, bags, backpacks, uniforms, umbrellas,swimwear, bed sheets, scarves, and many others.

A manufacturer creates a design 115 (design I) of its product. Thedesign can be for a particular type of clothing or garment (e.g., men'sor women's jean, or jacket), sizing of the garment (e.g., small, medium,or large, or waist size and inseam length), or other design feature. Thedesign can be specified by a pattern or cut used to form pieces of thepattern. A fabric is selected and patterned and cut 118 based on thedesign. The pattern pieces are assembled together 121 into the garment,typically by sewing, but can be joined together using other techniques(e.g., rivets, buttons, zipper, hoop and loop, adhesives, or othertechniques and structures to join fabrics and materials together).

Some garments can be complete after assembly and ready for sale.However, other garments are unfinished 122 and have additional finishing124, which includes laser finishing. The finishing may include tinting,washing, softening, and fixing. For distressed denim products, thefinishing can include using a laser to produce a wear pattern accordingto a design 127 (design II). Some additional details of laser finishingare described in U.S. patent application 62/377,447, filed Aug. 19,2016, and Ser. No. 15/682,507, filed Aug. 21, 2017, are incorporated byreference along with all other references cited in this application.

Design 127 is for postassembly aspects of a garment while design 115 isfor preassembly aspects of a garment. After finishing, a finishedproduct 130 (e.g., a pair of jeans) is complete and ready for sale. Thefinished product is inventoried and distributed 133, delivered to stores136, and sold to consumers or customers 139. The consumer can buy andwear worn blue jeans without having to wear out the jeans themselves,which usually takes significant time and effort.

Traditionally, to produce distressed denim products, finishingtechniques include dry abrasion, wet processing, oxidation, or othertechniques, or combinations of these, to accelerate wear of the materialin order to produce a desired wear pattern. Dry abrasion can includesandblasting or using sandpaper. For example, some portions or localizedareas of the fabric are sanded to abrade the fabric surface. Wetprocessing can include washing in water, washing with oxidizers (e.g.,bleach, peroxide, ozone, or potassium permanganate), spraying withoxidizers, washing with abrasives (e.g., pumice, stone, or grit).

These traditional finishing approaches take time, incur expense, andimpact the environment by utilizing resources and producing waste. It isdesirable to reduce water and chemical usage, which can includeeliminating the use agents such as potassium permanganate and pumice. Analternative to these traditional finishing approaches is laserfinishing.

FIG. 2 shows a finishing technique 124 that includes the use of a laser207. A laser is a device that emits light through a process of opticalamplification based on the stimulated emission of electromagneticradiation. Lasers are used for bar code scanning, medical proceduressuch as corrective eye surgery, and industrial applications such aswelding. A particular type of laser for finishing apparel is a carbondioxide laser, which emits a beam of infrared radiation.

The laser is controlled by an input file 210 and control software 213 toemit a laser beam onto fabric at a particular position or location at aspecific power level for a specific amount of time. Further, the powerof the laser beam can be varied according to a waveform such as a pulsewave with a particular frequency, period, pulse width, or othercharacteristic. Some aspects of the laser that can be controlled includethe duty cycle, frequency, marking or burning speed, and otherparameters.

The duty cycle is a percentage of laser emission time. Some examples ofduty cycle percentages include 40, 45, 50, 55, 60, 80, and 100 percent.The frequency is the laser pulse frequency. A low frequency might be,for example, 5 kilohertz, while a high frequency might be, for example,25 kilohertz. Generally, lower frequencies will have higher surfacepenetration than high frequencies, which has less surface penetration.

The laser acts like a printer and “prints,” “marks,” or “burns” a wearpattern (specified by input file 210) onto the garment. The fabric thatis exposed to the laser beam (e.g., infrared beam) changes color,lightening the fabric at a specified position by a certain amount basedon the laser power, time of exposure, and waveform used. The lasercontinues from position to position until the wear pattern is completelyprinted on the garment.

In a specific implementation, the laser has a resolution of about 34dots per inch (dpi), which on the garment is about 0.7 millimeters perpixel. The technique described in this patent is not dependent on thelaser's resolution, and will work with lasers have more or lessresolution than 34 dots per inch. For example, the laser can have aresolution of 10, 15, 20, 25, 30, 40, 50, 60, 72, 80, 96, 100, 120, 150,200, 300, or 600 dots per inch, or more or less than any of these orother values. Typically, the greater the resolution, the finer thefeatures that can be printed on the garment in a single pass. By usingmultiple passes (e.g., 2, 3, 4, 5, or more passes) with the laser, theeffective resolution can be increased. In an implementation, multiplelaser passes are used.

Jeans are dyed using an indigo dye, which results in a blue coloredfabric. The blue color is caused by chromophores trapped in the fabricwhich reflect light as a blue color. U.S. patent applications62/433,739, filed Dec. 13, 2016, and Ser. No. 15/841,263, filed Dec. 13,2017, which are incorporated by reference, describe a denim materialwith enhanced response characteristics to laser finishing. Using a denimmaterial made from indigo ring-dyed yarn, variations in highs and lowsin indigo color shading is achieved by using a laser.

U.S. patent applications 62/715,788, filed Aug. 7, 2018; 62/636,108,62/636,107, and 62/636,112, filed Feb. 27, 2018; Ser. No. 15/682,507,filed Aug. 21, 2017; Ser. No. 15/841,268, filed Dec. 13, 2017; and62/579,863 and 62/579,867, filed Oct. 31, 2017 are incorporated byreference.

Laser finishing can be used on denim and also other materials too. Laserfinishing can be used to alter the coloration of any material where thesublimation (or decomposition in some cases) temperature of the dye orthe material itself is within range of the operating temperatures of thelaser during use. Color change is a product of either the removal ofdyestuff or the removal of material uncovering material of anothercolor.

FIG. 3 shows a weave pattern of a denim fabric 326. A loom does theweaving. In weaving, warp is the lengthwise or longitudinal yarn orthread in a roll, while weft or woof is the transverse thread. The weftyarn is drawn through the warp yarns to create the fabric. In FIG. 3,the warps extend in a first direction 335 (e.g., north and south) whilethe wefts extend in a direction 337 (e.g., east and west). The wefts areshown as a continuous yarn that zigzags across the wefts (e.g., carriedacross by a shuttle or a rapier of the loom). Alternatively, the weftscould be separate yarns. In some specific implementations, the warp yarnhas a different weight or thickness than the weft yarns. For example,warp yarns can be coarser than the weft yarns.

For denim, dyed yarn is used for the warp, and undyed or white yarn istypically used for the weft yarn. In some denim fabrics, the weft yarncan be dyed and have a color other than white, such as red. In the denimweave, the weft passes under two or more warp threads.

FIG. 3 shows a weave with the weft passing under two warp threads.Specifically, the fabric weave is known as a 2×1 right-hand twill. For aright-hand twill, a direction of the diagonal is from a lower left to anupper right. For a left-hand twill, a direction of the diagonal is froman lower right to an upper left. But in other denim weaves, the weft canpass under a different number of warp threads, such as 3, 4, 5, 6, 7, 8,or more. In another implementation, the denim is a 3×1 right-hand twill,which means the weft passes under three warp threads.

Because of the weave, one side of the fabric exposes more of the warpyarns (e.g., warp-faced side), while the other side exposes more of theweft yarns (e.g., weft-faced side). When the warp yarns are blue andweft yarns are white, a result of the weave is the warp-faced side willappear mostly blue while the reverse side, weft-faced side, will appearmostly white.

In denim, the warp is typically 100 percent cotton. But some warp yarnscan be a blend with, for example, elastane to allow for warp stretch.And some yarns for other fabrics may contain other fibers, such aspolyester or elastane as examples.

In an indigo ring-dyed yarn, the indigo does not fully penetrate to acore of the yarn. Rather, the indigo dye is applied at a surface of thecotton yarn and diffuses toward the interior of the yarn. So when theyarn is viewed cross-sectionally, the indigo dyed material will appearas a ring on around an outer edge of the yarn. The shading of the indigodye will generally lighten in a gradient as a distance increases fromthe surface of the yarn to the center (or core) of the yarn.

During laser finishing, the laser removes a selected amount of thesurface of the indigo dyed yarn (e.g., blue color) to reveal a lightercolor (e.g., white color) of the inner core of the ring-dyed yarn. Themore of the indigo dyed material that is removed, the lighter the color(e.g., lighter shade of blue). The more of the indigo dyed material thatremains, the darker the color (e.g., deeper shade of blue). The lasercan be controlled precisely to remove a desired amount of material toachieve a desired shade of blue in a desired place or position on thematerial.

With laser finishing, a finish can be applied (e.g., printed or burnedvia the laser) onto apparel (e.g., jeans and denim garments) that willappear similar to or indistinguishable from a finish obtained usingtraditional processing techniques (e.g., dry abrasion, wet processing,and oxidation). Laser finishing of apparel is less costly and is fasterthan traditional finishing techniques and also has reduced environmentalimpact (e.g., eliminating the use of harsh chemical agents and reducingwaste).

FIGS. 4-7 show how the laser alters the color of ring-dyed yarn. FIG. 4shows a laser beam 407 striking a ring-dyed yarn 413 having indigo-dyedfibers 418 and white core fibers 422. The laser removes the dyed fibers,which can be by vaporizing or otherwise destroying the cotton fiber viaheat or high temperature that the laser beam causes.

FIG. 5 shows the laser using a first power level setting or firstexposure time setting, or a combination of these, to remove some of thedyed fibers, but not revealing any of the white core fibers. The undyedfibers remain covered. There is no color change.

FIG. 6 shows the laser using a second power level setting or secondexposure time setting, or a combination of these, to remove more of thedyed fibers than in FIG. 5. The second power level is greater than thefirst power level, or the second exposure time setting is greater thanthe first exposure time setting, or a combination of these. The resultis some of the undyed fibers are revealed. There is a color change,subtle highlighting.

FIG. 7 shows the laser using a third power level setting or thirdexposure time setting, or a combination of these, to remove even more ofthe dyed fibers than in FIG. 6. The third power level is greater thanthe second power level, or the third exposure time setting is greaterthan the second exposure time setting, or a combination of these. Theresult is more of the undyed fibers are revealed. There is a colorchange, brighter highlighting.

As shown in FIG. 2, before laser 207, the fabric can be prepared 216 forthe laser, which may be referred to as a base preparation, and caninclude a prelaser wash. This step helps improves the results of thelaser. After the laser, there can be a postlaser wash 219. This wash canclean or remove any residue caused by the laser, such as removing anycharring (which would appear as brown or slightly burning). By thepostlaser machine washing, the coloration due to the charring will beremoved. There can be additional finish 221, which may be includingtinting, softening, or fixing, to complete finishing.

Damage (e.g., holes, openings, or rips) can also be burned by the laseronto a garment. After lasering, the damage will appear as a whitish oryellowish region on the garment, because the laser has removed orlargely removed the indigo warp yarn or its indigo-colored outer ringwhile leaving or mostly leaving the whitish color of the inner core orthe white (or other color) weft yarn material, or both. The damage holeis not yet open and still joined together by the fine strands of yarn.However, after postlaser wash, due to the mechanical action of machinewashing, the damage on the garment will open up have a shreddedappearance which results from because the fine yarn strands are broken.Damage assets are discussed further in U.S. patent application Ser. No.16/177,387, filed Oct. 31, 2018, and 62/579,863, filed Oct. 31, 2017,which are incorporated by reference.

FIG. 8 shows a technique where finishing 124 is divided into twofinishing steps, finishing I and finishing II. Finishing I 808 is aninitial finishing to create base templates 811. With finishing II 814,each base template can be used to manufacture multiple final finishes817.

FIG. 9 shows multiple base templates, base A, base B, and base C. Thesebase templates may be referred to as base fit fabrics or BFFs. In animplementation, the base templates can be created during base prep andprelaser wash 216 (see FIG. 2). During finishing I, by using differentwash 216 methods or recipes, each different base template can becreated.

Finishing II can include laser finishing. Base A is lasered withdifferent designs to obtain various final product based on base A (e.g.,FP(A)1 to FP(A)i, where i is an integer). Base B is lasered withdifferent designs to obtain various final product based on base B (e.g.,FP(B)1 to FP(B)j, where j is an integer). Base C is lasered withdifferent designs to obtain various final product based on base C (e.g.,FP(C)1 to FP(C)k, where k is an integer). Each base can be used toobtain a number of different final designs. For example, the integers i,j, and k can have different values.

As described above and shown in FIG. 2, after finishing II, there can beadditional finishing during post laser wash 219 and additional finishing221. For example, during the postlaser wash, there may be additionaltinting to the lasered garments. This tinting can result in an overallcolor cast to change the look of the garment.

In an implementation, laser finishing is used to create many differentfinishes (each a different product) easily and quickly from the samefabric template or BFF or “blank.” For each fabric, there will be anumber of base fit fabrics. These base fit fabrics are lasered toproduce many different finishes, each being a different product for aproduct line. Laser finishing allows greater efficiency because by usingfabric templates (or base fit fabrics), a single fabric or material canbe used to create many different products for a product line, more thanis possible with traditional processing. This reduces the inventory ofdifferent fabric and finish raw materials.

For a particular product (e.g., 511 product), there can be two differentfabrics, such as base B and base C of FIG. 9. The fabrics can be part ofa fabric tool kit. For base B, there are multiple base fit fabrics,FP(B)1, FP(B)2, and so forth. Using laser finishing, a base fit fabric(e.g., FP(B)1) can be used to product any number of different finishes(e.g., eight different finishes), each of which would be considered adifferent product model.

For example, FP(B)1 can be laser finished using different laser files(e.g., laser file 1, laser file 2, laser file 3, or others) or havedifferent postlaser wash (e.g., postlaser wash recipe 1, postlaser washrecipe 2, postlaser wash recipe 3, or others), or any combination ofthese. A first product would be base fit fabric FP(B)1 lasered usinglaser file 1 and washed using postlaser wash recipe 1. A second productwould be base fit fabric FP(B)1 lasered using laser file 2 and washedusing postlaser wash recipe 1. A third product would be base fit fabricFP(B)1 lasered using laser file 2 and washed using postlaser wash recipe2. And there can be many more products based on the same base fitfabric. Each can have a different product identifier or uniqueidentifier, such as a different PC9 or nine-digit product code.

With laser finishing, many products or PC9s are produced for each basefit fabric or blank. Compared to traditional processing, this is asignificant improvement in providing greater numbers of differentproducts with less different fabrics and finishes (each of which intraditional processing consume resources, increasing cost, and taketime). Inventory is reduced. The technique of providing base fitfinishes or fabric templates for laser finishing has significant andmany benefits.

Greater numbers of products can be achieved by using, changing, orvarying the amount of damage. For example, from the same base fitfabric, there can be a first finished garment product FP(B)D0 withoutdamage. A second finished garment product FP(B)D1 can have damage in afirst particular positioning or first level (e.g., less damage orsmaller holes). A third finished garment product FP(B)D2 can have damagein a second particular position (different from the first particularpositioning) or second level (e.g., more damage or larger holes). Inthis way, more products can be obtained from the same base. And evenmore products can be obtained by combining varying damage and othervariables, such as postlaser wash recipe, laser finish pattern, andtinting during postlaser wash (or may applied by, for example, spraying,just before postlaser wash).

Tinting can be used to give garments a used, vintage, or muddyappearance. Greater numbers of products can be achieved by using,changing, or varying the amount of tinting after laser finishing, suchas during postlaser wash or applying, for example, by spraying, justbefore postlaser wash. For example, tinting is available in manydifferent colors and shades of colors. Some examples of tinting colorsinclude yellow, ecru, brown, red, green, blue, pink, cyan, magenta, andblack. Tinting is used to change hue, cast, or tone of the indigo.

For example, from the same base fit fabric, there can be a firstfinished garment product FP(B)T0 without tint. A second finished garmentproduct FP(B)T1 can tinting of a first color or first level. A thirdfinished garment product FP(B)T2 can have tinting of a second color orsecond level, different from the second finished garment product. Inthis way, more products can be obtained from the same base. And evenmore products can be obtained by combining tinting and varying damageand other variables.

A system incorporating laser finishing can include a computer to controlor monitor operation, or both. FIG. 10 shows an example of a computerthat is component of a laser finishing system. The computer may be aseparate unit that is connected to a system, or may be embedded inelectronics of the system. In an embodiment, the invention includessoftware that executes on a computer workstation system or server, suchas shown in FIG. 10.

FIG. 10 is a simplified block diagram of a distributed computer network1000 incorporating an embodiment of the present invention. Computernetwork 1000 includes a number of client systems 1013, 1016, and 1019,and a server system 1022 coupled to a communication network 1024 via aplurality of communication links 1028. Communication network 1024provides a mechanism for allowing the various components of distributednetwork 1000 to communicate and exchange information with each other.

Communication network 1024 may itself be comprised of manyinterconnected computer systems and communication links. Communicationlinks 1028 may be hardwire links, optical links, satellite or otherwireless communications links, wave propagation links, or any othermechanisms for communication of information. Communication links 1028may be DSL, Cable, Ethernet or other hardwire links, passive or activeoptical links, 3G, 3.5G, 4G and other mobility, satellite or otherwireless communications links, wave propagation links, or any othermechanisms for communication of information.

Various communication protocols may be used to facilitate communicationbetween the various systems shown in FIG. 10. These communicationprotocols may include VLAN, MPLS, TCP/IP, Tunneling, HTTP protocols,wireless application protocol (WAP), vendor-specific protocols,customized protocols, and others. While in one embodiment, communicationnetwork 1024 is the Internet, in other embodiments, communicationnetwork 1024 may be any suitable communication network including a localarea network (LAN), a wide area network (WAN), a wireless network, anintranet, a private network, a public network, a switched network, andcombinations of these, and the like.

Distributed computer network 1000 in FIG. 10 is merely illustrative ofan embodiment incorporating the present invention and does not limit thescope of the invention as recited in the claims. One of ordinary skillin the art would recognize other variations, modifications, andalternatives. For example, more than one server system 1022 may beconnected to communication network 1024. As another example, a number ofclient systems 1013, 1016, and 1019 may be coupled to communicationnetwork 1024 via an access provider (not shown) or via some other serversystem.

Client systems 1013, 1016, and 1019 typically request information from aserver system which provides the information. For this reason, serversystems typically have more computing and storage capacity than clientsystems. However, a particular computer system may act as both as aclient or a server depending on whether the computer system isrequesting or providing information. Additionally, although aspects ofthe invention have been described using a client-server environment, itshould be apparent that the invention may also be embodied in astand-alone computer system.

Server 1022 is responsible for receiving information requests fromclient systems 1013, 1016, and 1019, performing processing required tosatisfy the requests, and for forwarding the results corresponding tothe requests back to the requesting client system. The processingrequired to satisfy the request may be performed by server system 1022or may alternatively be delegated to other servers connected tocommunication network 1024.

Client systems 1013, 1016, and 1019 enable users to access and queryinformation stored by server system 1022. In a specific embodiment, theclient systems can run as a standalone application such as a desktopapplication or mobile smartphone or tablet application. In anotherembodiment, a “Web browser” application executing on a client systemenables users to select, access, retrieve, or query information storedby server system 1022. Examples of Web browsers include the InternetExplorer browser program provided by Microsoft Corporation, Firefoxbrowser provided by Mozilla, Chrome browser provided by Google, Safaribrowser provided by Apple, and others.

In a client-server environment, some resources (e.g., files, music,video, or data) are stored at the client while others are stored ordelivered from elsewhere in the network, such as a server, andaccessible via the network (e.g., the Internet). Therefore, the user'sdata can be stored in the network or “cloud.” For example, the user canwork on documents on a client device that are stored remotely on thecloud (e.g., server). Data on the client device can be synchronized withthe cloud.

FIG. 11 shows an exemplary client or server system of the presentinvention. In an embodiment, a user interfaces with the system through acomputer workstation system, such as shown in FIG. 11. FIG. 11 shows acomputer system 1101 that includes a monitor 1103, screen 1105,enclosure 1107 (may also be referred to as a system unit, cabinet, orcase), keyboard or other human input device 1109, and mouse or otherpointing device 1111. Mouse 1111 may have one or more buttons such asmouse buttons 1113.

It should be understood that the present invention is not limited anycomputing device in a specific form factor (e.g., desktop computer formfactor), but can include all types of computing devices in various formfactors. A user can interface with any computing device, includingsmartphones, personal computers, laptops, electronic tablet devices,global positioning system (GPS) receivers, portable media players,personal digital assistants (PDAs), other network access devices, andother processing devices capable of receiving or transmitting data.

For example, in a specific implementation, the client device can be asmartphone or tablet device, such as the Apple iPhone (e.g., AppleiPhone 6), Apple iPad (e.g., Apple iPad, Apple iPad Pro, or Apple iPadmini), Apple iPod (e.g, Apple iPod Touch), Samsung Galaxy product (e.g.,Galaxy S series product or Galaxy Note series product), Google Nexus andPixel devices (e.g., Google Nexus 6, Google Nexus 7, or Google Nexus 9),and Microsoft devices (e.g., Microsoft Surface tablet). Typically, asmartphone includes a telephony portion (and associated radios) and acomputer portion, which are accessible via a touch screen display.

There is nonvolatile memory to store data of the telephone portion(e.g., contacts and phone numbers) and the computer portion (e.g.,application programs including a browser, pictures, games, videos, andmusic). The smartphone typically includes a camera (e.g., front facingcamera or rear camera, or both) for taking pictures and video. Forexample, a smartphone or tablet can be used to take live video that canbe streamed to one or more other devices.

Enclosure 1107 houses familiar computer components, some of which arenot shown, such as a processor, memory, mass storage devices 1117, andthe like. Mass storage devices 1117 may include mass disk drives, floppydisks, magnetic disks, optical disks, magneto-optical disks, fixeddisks, hard disks, CD-ROMs, recordable CDs, DVDs, recordable DVDs (e.g.,DVD-R, DVD+R, DVD-RW, DVD+RW, HD-DVD, or Blu-ray Disc), flash and othernonvolatile solid-state storage (e.g., USB flash drive or solid statedrive (SSD)), battery-backed-up volatile memory, tape storage, reader,and other similar media, and combinations of these.

A computer-implemented or computer-executable version or computerprogram product of the invention may be embodied using, stored on, orassociated with computer-readable medium. A computer-readable medium mayinclude any medium that participates in providing instructions to one ormore processors for execution. Such a medium may take many formsincluding, but not limited to, nonvolatile, volatile, and transmissionmedia. Nonvolatile media includes, for example, flash memory, or opticalor magnetic disks. Volatile media includes static or dynamic memory,such as cache memory or RAM. Transmission media includes coaxial cables,copper wire, fiber optic lines, and wires arranged in a bus.Transmission media can also take the form of electromagnetic, radiofrequency, acoustic, or light waves, such as those generated duringradio wave and infrared data communications.

For example, a binary, machine-executable version, of the software ofthe present invention may be stored or reside in RAM or cache memory, oron mass storage device 1117. The source code of the software of thepresent invention may also be stored or reside on mass storage device1117 (e.g., hard disk, magnetic disk, tape, or CD-ROM). As a furtherexample, code of the invention may be transmitted via wires, radiowaves, or through a network such as the Internet.

FIG. 12 shows a system block diagram of computer system 1101 used toexecute the software of the present invention. As in FIG. 11, computersystem 1101 includes monitor 1103, keyboard 1109, and mass storagedevices 1117. Computer system 1101 further includes subsystems such ascentral processor 1202, system memory 1204, input/output (I/O)controller 1206, display adapter 1208, serial or universal serial bus(USB) port 1212, network interface 1218, and speaker 1220. The inventionmay also be used with computer systems with additional or fewersubsystems. For example, a computer system could include more than oneprocessor 1202 (i.e., a multiprocessor system) or a system may include acache memory.

Arrows such as 1222 represent the system bus architecture of computersystem 1101. However, these arrows are illustrative of anyinterconnection scheme serving to link the subsystems. For example,speaker 1220 could be connected to the other subsystems through a portor have an internal direct connection to central processor 1202. Theprocessor may include multiple processors or a multicore processor,which may permit parallel processing of information. Computer system1101 shown in FIG. 12 is but an example of a computer system suitablefor use with the present invention. Other configurations of subsystemssuitable for use with the present invention will be readily apparent toone of ordinary skill in the art.

Computer software products may be written in any of various suitableprogramming languages, such as C, C++, C #, Pascal, Fortran, Perl,Matlab (from MathWorks, www.mathworks.com), SAS, SPSS, JavaScript, AJAX,Java, Python, Erlang, and Ruby on Rails. The computer software productmay be an independent application with data input and data displaymodules. Alternatively, the computer software products may be classesthat may be instantiated as distributed objects. The computer softwareproducts may also be component software such as Java Beans (from OracleCorporation) or Enterprise Java Beans (EJB from Oracle Corporation).

An operating system for the system may be one of the Microsoft Windows®family of systems (e.g., Windows 95, 98, Me, Windows NT, Windows 2000,Windows XP, Windows XP x64 Edition, Windows Vista, Windows 7, Windows 8,Windows 10, Windows CE, Windows Mobile, Windows RT), Symbian OS, Tizen,Linux, HP-UX, UNIX, Sun OS, Solaris, Mac OS X, Apple iOS, Android, AlphaOS, AIX, IRIX32, or IRIX64. Other operating systems may be used.Microsoft Windows is a trademark of Microsoft Corporation.

Any trademarks or service marks used in this patent are property oftheir respective owner. Any company, product, or service names in thispatent are for identification purposes only. Use of these names, logos,and brands does not imply endorsement.

Furthermore, the computer may be connected to a network and mayinterface to other computers using this network. The network may be anintranet, internet, or the Internet, among others. The network may be awired network (e.g., using copper), telephone network, packet network,an optical network (e.g., using optical fiber), or a wireless network,or any combination of these. For example, data and other information maybe passed between the computer and components (or steps) of a system ofthe invention using a wireless network using a protocol such as Wi-Fi(IEEE standards 802.11, 802.11a, 802.11b, 802.11e, 802.11g, 802.11i,802.11n, 802.11ac, and 802.11ad, just to name a few examples), nearfield communication (NFC), radio-frequency identification (RFID), mobileor cellular wireless (e.g., 2G, 3G, 4G, 3GPP LTE, WiMAX, LTE, LTEAdvanced, Flash-OFDM, HIPERMAN, iBurst, EDGE Evolution, UMTS, UMTS-TDD,ixRDD, and EV-DO). For example, signals from a computer may betransferred, at least in part, wirelessly to components or othercomputers.

In an embodiment, with a Web browser executing on a computer workstationsystem, a user accesses a system on the World Wide Web (WWW) through anetwork such as the Internet. The Web browser is used to download Webpages or other content in various formats including HTML, XML, text,PDF, and postscript, and may be used to upload information to otherparts of the system. The Web browser may use uniform resourceidentifiers (URLs) to identify resources on the Web and hypertexttransfer protocol (HTTP) in transferring files on the Web.

In other implementations, the user accesses the system through either orboth of native and nonnative applications. Native applications arelocally installed on the particular computing system and are specific tothe operating system or one or more hardware devices of that computingsystem, or a combination of these. These applications (which aresometimes also referred to as “apps”) can be updated (e.g.,periodically) via a direct internet upgrade patching mechanism orthrough an applications store (e.g., Apple iTunes and App store, GooglePlay store, Windows Phone store, and Blackberry App World store).

The system can run in platform-independent, nonnative applications. Forexample, client can access the system through a Web application from oneor more servers using a network connection with the server or serversand load the Web application in a Web browser. For example, a Webapplication can be downloaded from an application server over theInternet by a Web browser. Nonnative applications can also be obtainedfrom other sources, such as a disk.

FIGS. 13-14 show examples of mobile devices, which can be mobileclients. Mobile devices are specific implementations of a computer, suchas described above. FIG. 13 shows a smartphone device 1301, and FIG. 14shows a tablet device 1401. Some examples of smartphones include theApple iPhone, Samsung Galaxy, and Google Nexus family of devices. Someexamples of tablet devices include the Apple iPad, Apple iPad Pro,Samsung Galaxy Tab, and Google Nexus family of devices.

Smartphone 1301 has an enclosure that includes a screen 1303, button1309, speaker 1311, camera 1313, and proximity sensor 1335. The screencan be a touch screen that detects and accepts input from finger touchor a stylus. The technology of the touch screen can be a resistive,capacitive, infrared grid, optical imaging, or pressure-sensitive,dispersive signal, acoustic pulse recognition, or others. The touchscreen is screen and a user input device interface that acts as a mouseand keyboard of a computer.

Button 1309 is sometimes referred to as a home button and is used toexit a program and return the user to the home screen. The phone mayalso include other buttons (not shown) such as volume buttons and on-offbutton on a side. The proximity detector can detect a user's face isclose to the phone, and can disable the phone screen and its touchsensor, so that there will be no false inputs from the user's face beingnext to screen when talking.

Tablet 1401 is similar to a smartphone. Tablet 1401 has an enclosurethat includes a screen 1403, button 1409, and camera 1413. Typically thescreen (e.g., touch screen) of a tablet is larger than a smartphone,usually 7, 8, 9, 10, 12, 13, or more inches (measured diagonally).

FIG. 15 shows a system block diagram of mobile device 1501 used toexecute the software of the present invention. This block diagram isrepresentative of the components of smartphone or tablet device. Themobile device system includes a screen 1503 (e.g., touch screen),buttons 1509, speaker 1511, camera 1513, motion sensor 1515, lightsensor 1517, microphone 1519, indicator light 1521, and external port1523 (e.g., USB port or Apple Lightning port). These components cancommunicate with each other via a bus 1525.

The system includes wireless components such as a mobile networkconnection 1527 (e.g., mobile telephone or mobile data), Wi-Fi 1529,Bluetooth 1531, GPS 1533 (e.g., detect GPS positioning), other sensors1535 such as a proximity sensor, CPU 1537, RAM memory 1539, storage 1541(e.g., nonvolatile memory), and battery 1543 (lithium ion or lithiumpolymer cell). The battery supplies power to the electronic componentsand is rechargeable, which allows the system to be mobile.

FIG. 16 shows a block diagram of a system for creating, designing,producing apparel products with laser finishing. A box line plan 1602 isan internal and interim tool for communication between a merchandisinggroup and design group. Through the box line plan, merchandising cancommunicate what needs to be designed by the design group. The box lineplan can have open slots to be designed 1609.

There is a digital design tool 1616 merchants and design can use toclick and drag finish effects (e.g., laser files) and tint casts overimages of base washes in order to visualize possible combinations andbuild the line visually before the garment finish is actually finishedby the laser. The visualizations can be by rendering on a computersystem, such as using three-dimensional (3-D or 3D) graphics.

U.S. patent application 62/433,746, filed Dec. 13, 2016, and Ser. No.15/841,268, filed Dec. 13, 2017, which are incorporated by reference,describe a system and operating model of apparel manufacture with laserfinishing. Laser finishing of apparel products allows an operating modelthat reduces finishing cost, lowers carrying costs, increasesproductivity, shortens time to market, be more reactive to trends,reduce product constraints, reduces lost sales and dilution, and more.Improved aspects include design, development, planning, merchandising,selling, making, and delivering. The model uses fabric templates, eachof which can be used be produce a multitude of laser finishes.Operational efficiency is improved.

Designers can use the digital design tool to design products that areused to satisfy the requests in open slots 1609. Designs created usingthe digital design tool can be stored in a digital library 1622. Inputto the digital design tool include fabric templates or blanks 1627(e.g., base fit fabrics or BFFs), existing finishes 1633 (e.g., can befurther modified by the tool 1616), and new finishes 1638. New finishescan be from designs 1641 (e.g., vintage design) captured using a laserfinish software tool 1645, examples of which are described in U.S.patent application 62/377,447, filed Aug. 19, 2016, and Ser. No.15/682,507, filed Aug. 21, 2017. Digital library 1622 can be accessibleby the region assorting and sell-in 1650. And the digital library can beused to populate or satisfy the box line plan.

FIG. 17 shows a block diagram of a specific implementation of a digitaldesign tool, a preview tool 1703. Digital design tool 1616 can berepresentative of a collection of tools, such as an application suite,including desktop or mobile apps, or a combination.

Preview tool 1703 can be a single tool in a toolbox or toolkit used forlaser finishing of garments, or the tool can be incorporated as afeature of another tool. The preview tool allows a user such as aclothing designer to preview on a computer screen or to generate adigital representation (e.g., image file, JPEG file, BMP file, TIFFfile, GIF file, PNG file, PSD file, or others) of jeans in a selectedbase fit fabric or fabric template 1706 with a selected laser pattern1709 (e.g., from a laser input file). With the digital representation,the user will be able to see or preview the jeans in the selected basefit fabric as if it had been burned with the selected laser input file,without needing to actually laser or burn the jeans.

With the preview tool, the appearance of the garment (e.g., jeans) willbe of the finished garment product that the consumer will see (e.g.,after postlaser wash). As discussed above, after laser finishing, thegarment will have charred appearance, and damage holes will still beconnected by fine yarns, and will not yet be tinted. After postlaserwash, the charring and yellowish hue due to the laser ash and residuewill be washed away. The damage holes or openings will be opened andtypically have a shredded appearance. The garment will have the selectedtinting (e.g., color and level of color).

The preview tool displays on a screen or other visual output a previewimage 1711 of the garment as it would appear to the consumer, after postlaser wash. The preview image 1711 will be a photorealistic image incolor. The preview image may be displayed in using a 8-bit or greatercolor depth, 16-bit or greater color depth, 24-bit or greater colordepth, or 32-bit or greater color depth. This is in contrast to acomputer screen at operator's console of a laser finishing machine,which typically only shows black and white images. The console isprimarily used for alignment rather than design, and using black andwhite images can provide increased contrast (as compared to colorimages) which aids the operator in achieving proper alignment.

The console is directly attached or connected to the laser, while thepreview tool is front end tool that executes remotely from the computerand connected via a network. The preview tool can be directly attachedor connected to the laser, but typically not because laser finishing istypically performed at a different physical location from where garmentsare designed. For example, a design facility may be in San Francisco,while the laser finishing center may be Las Vegas or outside the UnitedStates (e.g., China, Mexico, Bangladesh, Sri Lanka, Vietnam, India,Malaysia, Indonesia, Egypt, Brazil, and others).

After a garment has been designed and previewed using the preview tool,the information can be transferred via the network to the laserfinishing tool and its console. For example, the preview tool canexecute on a desktop computer, mobile device (e.g., smartphone or tabletcomputer), or using a Web browser.

Some files are described as being of an image file type. Some examplesof image file types or file formats include bitmap or raster graphicsformats including IMG, TIFF, EXIF, JPEG, GIF, PNG, PBM, PGM, PPM, BMP,and RAW. The compression for the file can be lossless (e.g., TIFF) orlossy (e.g., JPEG). Other image file types or file formats includevector graphics including DXF, SVG, and the like.

Bitmaps or raster graphics are resolution dependent while vectorgraphics are resolution independent. Raster graphics generally cannotscale up to an arbitrary resolution without loss of apparent quality.This property contrasts with the capabilities of vector graphics, whichgenerally easily scale up to the quality of the device rendering them.

A raster graphics image is a dot matrix data structure representing agenerally rectangular grid of pixels, or points of color, viewable via amonitor, paper, or other display medium. A bitmap, such as a single-bitraster, corresponds bit-for-bit with an image displayed on a screen oroutput medium. A raster is characterized by the width and height of theimage in pixels and by the number of bits per pixel (or color depth,which determines the number of colors it can represent).

The BMP file format is an example of a bitmap. The BMP file format, alsoknown as bitmap image file or device independent bitmap (DIB) fileformat or simply a bitmap, is a raster graphics image file format usedto store bitmap digital images, independently of the display device. TheBMP file format is capable of storing two-dimensional digital images ofarbitrary width, height, and resolution, both monochrome and color, invarious color depths, and optionally with data compression, alphachannels, and color profiles.

The fabric template can be selected from a library of fabric templateimages 1716 or may be a new image uploaded or provided by the user. Eachfabric template images is an image file of a jeans in a base fit fabricor other material. For each jeans model or fit (e.g., models or fits311, 501, 505, 511, 515, 541, 569, 721, and others), there would be oneimage in each different material or base fit fabric.

The laser input file can be selected from a library of laser input files1722 (e.g., files created from vintage jeans or from a group ofdesigners), a file 1718 created by the user, or a file uploaded orprovided by the user. For example, the user may have created the laserpattern (contained within a laser input file) manually using a graphicalor image editing tool (e.g., Adobe Photoshop and similar photo editingprograms). Or the laser pattern may have been created by another, suchas selected from a library of laser files. The laser pattern may begenerated by a computer or automated process, such as may be used toobtain a laser pattern from vintage jeans. The user will be able to seethe results of a burn, make any manual changes or alterations to thepattern (such as additional changes to a vintage jean pattern in adigital image file) and preview the results again. The preview toolallows a user to make and see changes, to the user can obtain feedbackfaster than having to laser jeans to see the results and also avoidingunneeded waste (e.g., preliminary versions of burned jeans).

Each digital representation can be saved as separate images, and a groupor set of the images can be a called brief of collection of jeans. Thepreview tool can be used for merchandising, such as generating images ofa proposed line of products for a particular season, and these imagescan be shared among members of a team to discuss any additions, changes,or deletions to a collection.

A table below presents a pseudocode computer program listing of samplesoftware code for a specific implementation of a preview tool 1703 fordisplaying finished apparel 1711 for a given fabric template input(e.g., base fit fabric image) and laser input file. A specificimplementation of the source code may be written in a programminglanguage such as Python. Other programming languages can be used.

TABLE PREVIEW PATTERN TOOL SETUP: file selection object GET: input filefrom user selection ASSIGN: default blur options for high and lowsettings ASSIGN: input and conversion dpi settings FUNCTION: Import File(File List, File Index): IMPORT: file being previewed COMPUTE AND SET:resolution conversion factor CALCULATE: optional resized image for useduring preview RETURN: input file and resized input file RUN: ImportFile (File List, File Index) CREATE: plotting object to display resultsto user SETUP: custom colors for preview options ASSIGN: color and colorseparation variables SETUP: graphical user interface interactionsbuttons, sliders, etc. FUNCTION: Update (Value): READ: current displaysettings CHECK: which user interactions are being changed ASSIGN:operation variable value PERFORM: user specified operation REDRAW: plotof image preview to user FUNCTION: Reset (Event): RESET: all defaultsettings for image preview FUNCTION: Change Color (color): SET: color ofbase color for preview REDRAW: plot of image preview to user PLOT:current state of file object

A specific version of the preview tool overlays a fabric template inputfile and a laser input file, and then generates an image to display themtogether as a representation of the laser-finished apparel. The laserinput file is aligned to the garment in the fabric template input file,so that the positioning of features in the laser input file are atappropriate positions or places on the garment. The alignment may be byusing alignment marks that are in the input files. The alignment may bean automated alignment or scaling, or a combination.

Brightness, intensity, opacity, blending, transparency, or otheradjustable parameters for an image layer, or any combination of these,are selected or adjusted for the laser input file, so that when thelaser input file is overlaid above the fabric template image, the lookof the garment will appear of simulate the look of a garment had beenburned by a laser using that laser input file.

Adjustable parameters such as opacity can be used to blend two or moreimage layers together. For example, a layer's overall opacity determinesto what degree it obscures or reveals the layer beneath it. For example,a layer with 1 percent opacity appears nearly transparent, while onewith 100 percent opacity appears completely opaque.

Further, a dots per inch (dpi) of the combined image can be adjusted tomore properly simulate the look of a garment more closely with a burnedgarment. Dots per inch refers to the number of dots in a printed inch.The more dots, the higher the quality of the print (e.g., more sharpnessand detail). By reducing the dpi of the image, this will reduce theimage quality, resulting a blurring of the image. In an implementation,the preview tool reduces a dpi of the combined image, to be of less dpithan the fabric template input file or the laser input file. By blurringthe preview image, this results in improved simulation that correspondsbetter to a burned laser garment. When burning a garment, the garmentmaterial or fabric typically limits the resolution of the result to lessthan that of the input file.

In an implementation, the dpi of the laser input file is about 72 dpi,while the dpi of the preview image is about 34 dpi. In animplementation, the dpi of the fabric template input file and laserinput file are about 36 dpi or above, while the dpi of the preview imageis about 36 dpi or lower.

FIG. 18 shows a block diagram of a digital brief tool 1803, which alsolike preview tool 1703, provides a real-time preview of an appearance ofpair of jeans when a finishing pattern is applied by burning using alaser input file. The digital brief tool has additional features toallow more flexible designing of jeans.

It should be understood that the invention is not limited to thespecific flows and steps presented. A flow of the invention may haveadditional steps (not necessarily described in this patent), differentsteps which replace some of the steps presented, fewer steps or a subsetof the steps presented, or steps in a different order than presented, orany combination of these. Further, the steps in other implementations ofthe invention may not be exactly the same as the steps presented and maybe modified or altered as appropriate for a particular application orbased on the data or situation.

As input, the digital brief tool takes three types of digital assets1805, fabric template input 1816, damage input 1819, and laser inputfile 1822. Fabric template input 1816 and laser input file 1822 aresimilar to the inputs for the preview tool. Damage input 1819 is animage of damage (e.g., holes, rips, shredded regions, or openings ofvarious shapes and sizes) that can be burned by a laser into jeans. Thedigital brief tool overlays the damage and laser input files over thefabric template.

The user selects a fabric template input, which an image of a jeansstyle in a particular base fit fabric. The user can optionally selectone or more damage inputs. If a damage input is selected, the damageinput will be a layer that overlays the fabric template layer. As forthe preview tool, the user selects a laser input file with laser patternand overlays the fabric template layer. As the user selects the inputs,the user will be able to see in real time the inputs and any changes orupdates in a preview image or brief.

After the inputs are selected, the user can select and perform one ormore operations 1826 on the inputs using the digital brief tool. Theseoperations including adding tint 1831, adjusting intensity 1834,adjusting bright point 1837, move digital asset 1842, rotate digitalasset 1845, scale digital asset 1848, and warp digital asset 1852. Asthe user selects and performs one or more operations, the user will beable to see in real time the changes or updates in the preview image orbrief.

After the fabric template input, the user can add tinting 1831. Tintingwill adjust the hue of the color of the fabric template input. Tintingis representative of the tinting which can be added during the postlaserwash or finishing II, described above. The user will be able to select atint color, and this tint color will be blended with the existing colorof the fabric template input. The amount or intensity of the tinting canbe increased or decreased, such as by using a slider bar.

The user can adjust intensity 1834. In an implementation, intensityadjusts a weight matrix by a percentage of each value in the array. Inan implementation, intensity (or brightness) adjusts an opacity of agenerated adjustment layer (see hue saturation lightness adjustmentlayer described below). The greater the opacity, the more opaque thislayer will appear in the preview or brief image. The less the opacity,the less opaque this layer will appear in the preview or brief image;the layer will appear more transparent so that the layer beneath willshow through more.

When increasing brightness, the opacity of the adjustment layerincreases, and since the adjustment layer is above the fabric templateinput, the generated adjustment layer will become more prominent orvisible, thus making this layer (which has the wear pattern) brighter.Similarly, when decreasing brightness, the opacity of the adjustmentlayer decreases, the generated adjustment layer will become lessprominent or visible, thus making this layer (which has the wearpattern) less bright or fainter. The amount of the intensity can beincreased or decreased, such as by using a slider bar.

The user can adjust bright point 1837. Bright point adjusts the effectof the laser input file on the fabric template input. In animplementation, bright point adjustment changes a midpoint of agrayscale, creating a piecewise linear mapping of the pattern file.

Increasing the bright point will increase an effect of the laser pattern(e.g., causing greater laser pattern highlights) in the laser input fileon the fabric template input, while decreasing the bright point does theopposite (e.g., diminishing laser pattern highlights). The bright pointadjustment can be analogous to changing a pixel time or the time thatthe laser stays at a particular position for a given input from thelaser input file. The amount of the bright point can be increased ordecreased, such as by using a slider bar.

The user can move 1842 or reposition a selected digital asset. Forexample, a damage input (or fabric template or laser file) may be movedto a position desired by the user. The user can rotate 1845 a selecteddigital asset. For example, a damage input (or fabric template or laserfile) may be rotated to any angle relative to the other layers asdesired by the user.

The user can scale 1848 a selected digital asset. This scaling can belocked, maintaining the original aspect ratio of the digital asset, orcan be unlocked, such that the user can change the aspect ratio. Theuser can warp 1852 a selected digital asset. With warping, the user canadjust an aspect ratio of a portion of the digital asset differentlyfrom another portion. For example, one portion of a damage input (orfabric template or laser file) can be squished (e.g., right and leftedges of image pushed toward each other) while another portion isexpanded (e.g., right and left edges of image pulled away from eachother).

After the user has performed selected operations 1826, the digital brieftool shows an image of the jeans with the laser finishing pattern,including any tinting, damage, or other adjustments, as created by theuser. This image can be saved and viewed again later. A user can createmultiple designs, and these can be saved together as part of acollection.

FIG. 19 shows a technique of generating a preview of a finished imageusing a digital brief tool. A base image (or fabric template input) isselected. A hue saturation lightness (HSL) adjustment layer is createdor generated for the selected base image. The HSL adjustment layer canbe the base layer with an adjustment for hue saturation lightness. Whentinting is selected, a solid color adjustment layer is created orgenerated.

To obtain a final result, which is the final image of the jeans withlaser finishing pattern, a laser pattern mask is combined with the baseimage and HSL adjustment layer. A resulting combination will be based onintensity and bright point settings.

The laser pattern mask is a negative image or reverse image of the laserinput file. For the laser input file, during laser burning, a whitepixel means the pixel is not lasered (which results in the originalindigo color of the fabric), and a black pixel means the pixel will belasered at highest level (which results in the whitest color that can beachieved on the fabric). In an implementation, the laser input file has256 levels of gray, and for levels between 0 (e.g., black) and 255(e.g., white), then the amount of laser burning will be proportionallysomewhere in between.

FIG. 20 shows a laser pattern mask that is created from a laser inputfile. The digital brief tool creates the laser pattern mask from thelaser input file by reversing the laser input file. So, for the laserpattern mask, a black pixel means the pixel is not lasered (whichresults in the original indigo color of the fabric), and a white pixelmeans the pixel will be lasered at the highest level (which results inthe whitest color that can be achieved on the fabric).

FIG. 21 shows an HLS adjustment layer that is created from the baseimage. The HLS adjustment layer (or adjustment layer) is like ableaching layer, which is an image of what the jeans would appear likeif the jeans were fully bleached or lasered. This layer is created bytaking the base image and adjusting its hue, saturation, and lightness.In an implementation, for this layer, the saturation is reduced comparedto the base layer, and the lightness is increased compared to the baselayer. And the hue is not adjusted compared to the base layer.

A technique of the digital brief tool is to combine the base image andadjustment layer based on the laser pattern mask. For a black pixel inthe laser pattern mask, the base layer will fully pass (and none of theadjustment layer) through to the final result image. For a white pixelin the laser pattern mask, the adjustment layer (and none of the baselayer) will fully pass through to the final result image. For gray pixelvalues, then a percentage of the base layer and adjustment layer willpass through to the final result image. For example, for a value in thelayer pattern mask, 90 percent of the base layer and 10 percent of theadjustment layer pass through to the final result image.

FIG. 22 shows a technique of creating a masked solid color adjustmentlayer. The digital brief tool creates the solid color adjustment layerby creating a layer of a solid color, mask this layer based on the baseimage, and then create masked solid color adjustment layer. An opacityof the masked solid color adjustment layer can be reduced, so that whencombined with the based image, the base image will pass through withsome tinting contributed by the masked solid color adjustment layer.

FIGS. 23-24 show examples of two different adjustments or settings for abright point operation. Adjusting bright point adjusts a rate oftransition from middle gray to white on the layer mask.

FIG. 25 shows adjustment of intensity. The intensity adjustment adjustsan opacity (e.g., 40 percent to 100 percent) of an HSL adjustment layer.At 100 percent, the HSL adjustment layer will be fully opaque, and thewear pattern will be very prominent in the brief image or preview.

FIG. 26 shows an array of images showing the effects of adjustments inbright point and intensity. Intensity changes are shown in an X or rowdirection, while bright point changes are shown in a Y or columndirection.

For a first jeans in the first column (from a left of the array), thirdrow (from a top of the array), the bright point and intensity are bothL, indicating the least amount of bright point and intensity. A secondjeans is in the second column, third row; this jeans has a bright pointof L and an intensity between L and H. The wear pattern of the secondjeans is more visible than that for the third jeans. A third jeans is inthe third column, third row; this jeans has a bright point of L and anintensity of H, indicating the greatest amount of intensity. The wearpattern of the third jeans is more visible than that for the secondjeans.

A fourth jeans is in the third column, second row; this jeans has abright point between L and H, and an intensity of H. The size or area ofthe wear pattern of the fourth jeans is larger than that for the thirdjeans. A fifth jeans is in the third column, first row; this jeans has abright point of H and an intensity of H. The size or area of the wearpattern of the fifth jeans is larger than that for the fourth jeans.

FIG. 27 shows a block diagram of a system of generating a preview of alaser-finishing pattern on a garment, such as jeans. Inputs to a createpreview image process 2702 include a base template image 2707 and laserinput file 2709. The base template image is used to create an adjustedbase template image 2717, which is also input to the create previewimage process. These create preview image process uses these threeinputs to create a preview image 2727, which can be displayed on acomputer screen for the user.

The adjusted base template image is created from the base template imageby adjusting its hue, saturation, or lightness, or any combination ofthese. Compared to the original base template image, the adjusted basetemplate image will appear washed out or bleached. In other words, theadjusted base template image will appear as if the garment in the basetemplate image were fully bleached or lasered. The adjusted basetemplate image can be an HLS adjustment layer as discussed above.

For a specific implementation of a laser, a specification for the laserinput file is that each pixel is represented by an 8-bit binary value,which represents grayscale value in a range from 0 to 255. A 0 blackprints the highest intensity (i.e., creates the most change and will bethe lightest possible pixel) and a 255 white does not print at all(i.e., creates the least change or will be the darkest possible pixel).

For a laser input file for this laser implementation, a reverse ornegative image of the laser input file is input to the create previewimage process. Based on the negative laser input file, to create eachpixel in the preview image, the create preview image process will passpixels of the base template image or the adjusted base template image,or a combination of these.

For the negative laser input file, a black pixel means the pixel (whichwas a white pixel in the original file) will not be lasered (whichresults in the original indigo color of the fabric). And a white pixelmeans the pixel (which was black in the original file) will be laseredat highest level (which results in the whitest color that can beachieved on the fabric). And for gray pixels between black and white,the result will be proportional to the value, somewhere between darkestand lightest colors.

Similarly, to create the preview image, based the negative laser inputfile, a pixel of a (1) base template image (e.g., unbleached) or (2)adjusted base template image (e.g., bleached) or (3) some mixture orcombination of the base template image and adjusted base template imageproportional to the grayscale value in the negative laser input file.For example, for a gray value in the negative laser input file, 60percent of the base layer and 40 percent of the adjustment layer passthrough to the preview image.

The above discussion described a laser input file conforming to one typeof logic. However, in other implementations of a laser, the values inthe laser input file can be the reverse or negative logic compared tothat described above. As one of ordinary skill in the art wouldappreciate, the techniques described in this patent can be modifiedaccordingly to work with negative or positive logic laser input files.

FIGS. 28-35E show an implementation of a three-dimensional (3-D or 3D)previewing feature of a laser finishing design tool, such as a digitalbrief tool (e.g., digital brief tool 1803 of FIG. 18). For example,after creating or selecting a product, the user can view the product(e.g., garment) in three dimensions or 3D. This 3D preview featureallows a user to see a 360-degree preview (in any direction ororientation) of a garment with a laser finishing pattern as the garmentwould appear when it is worn by a person.

The preview can be shown with a simulated light source, where apositioning of the simulated light source can be moved by the user. Or,the simulated light source can be at a particular position, and the usercan move the garment above the simulated light source. The preview imagewill appear with the shadows based on the positioning of the lightsource.

Additionally, the preview image can be used in the digital brief tool orother tools where it is desirable for users to view previews ofgarments. Some examples include a consumer sales or ordering Web site(e.g., such as a preview available through a Web browser), where thethree-dimensional preview allows the user to see the garment beforemaking the order. Another example is a sales for wholesalers,distributors, retailers, and other buyers of a manufacturers product.The three-dimensional preview can provide the buyers a realistic view ofthe garments to be ordered, without needing to make physical samples oras many physical samples.

FIG. 28 shows an overall flow for creating a three-dimensional previewfor an apparel product, such as a pair of jeans. The flow includes:

1. A deconstruct garment step 2806. A garment is cut into separatepieces so the pieces can be photographed flat. The shape of the cutpieces are specifically sized and selected for ensuring a high qualitythree-dimensional preview.

2. A photograph pattern pieces step 2812. The pieces of the garment arephotographed while flat on a surface. Compared to photographing thepieces while sewed together, where sections of the garment may be

3. An extract shadow neutral digital pattern pieces 2818.

4. A create shadow neutral texture pieces 2824.

5. A map shadow neutral texture to three-dimensional (3-D or 3D) modelstep 2830.

6. An apply simulated light or shadowing, or both, step 2836.

The following describes a specific implementation of deconstruct garment2806. FIGS. 29A-29F show photographs of cutting a garment into pieces.The photos are for a specific implementation where the garment is a pairor pants, and in particular, a pair of jeans. Not that the seams are notripped or cut, but rather the cut pieces include the seams with thread.This ensures the three-dimensional preview will represent the seamsproperly. Also the cut pieces do not necessarily correspond to thepattern panels used to contrast the garment. The cut pieces are cut intoshapes that are appropriate for photographing flat and use in generatingthe three-dimensional preview.

The following describes a specific implementation of photograph patternpieces 2812. A photograph of each deconstructed pattern pieces is taken.Each photograph can be stored in a digital file, such as a JPEG, highefficiency video coding (HVEC), or other image file format.

FIG. 30 shows a system for taking photographs of the garment pieces. Thesystem includes a camera 3009 and lighting 3012 and 3016. Typically thecamera and lights are mounted or positioned against or near a wall orceiling of a room, or on one side of room. A garment or garment pieces3027 that are to be photographed are laid flat on a surface, facing thecamera and lighting. In an implementation, the camera and lightning arepositioned above a table or other work surface 3029, horizontallyorientated, upon which the garment is placed.

Alternatively, the camera and lightning are positioned on a side, andthe work surface is vertically orientated on another side facing thecamera and lightning. The garment pieces that be attached, such as usingglue, pins, or hook and loop fasteners, to the vertical work surface.

The room can be a light room or light box. The room and work surface aretypically painted or colored a white color. For good or best results,the white color used should be consistently the same shade throughoutthe room. Then any white balance adjustment or correction made at thecamera or digitally after the photographs are taken will be moreprecise.

The lights of the lightning are positioned laterally (e.g., distributedevenly along the same plane as the work surface, which can be referredas an X direction) to evenly illuminate the work surface. So, thegarment will be evenly illuminated without noticeably or significantlybrighter or darker areas or portions. The lightning is also positioned adistance above the work surface (which can be referred as a Y direction)to allow for more even illumination.

The lens of the camera is positioned above (in the Y direction) thelighting source, so that the camera does not cast a shadow on the worksurface or garment (e.g., horizontally orientated). And the camera canbe positioned in the X direction so that lights are arranged uniformlyabout the camera lens. For example, in FIG. 30, camera 3009 is betweenlights 3012 and 3016. Also the camera lens should be positioned directlyover the garment (in the X direction) being photographed. This ensuresthe photographs taken will not be at an angle.

A specific example of extract shadow neutral digital pattern pieces 2818follows.

After the photographs are taken, each photograph is processed to extractneutral digital pattern pieces. In the extraction process, thebackground and shadowing, if any, is removed.

As examples, FIGS. 31A-31B show photographs of a waistband pieces on thework surface, and FIG. 31C shows the extracted neutral digital patternpiece for the waistband. The physical waistband may be cut into multiplepieces, and the photographs of the separate pieces can be digitallystitched together to create the complete extracted neutral digitalwaistband.

FIG. 31D shows a photograph of a left pant leg front of a pair of jeanswith the background, and FIG. 31E shows the extracted neutral digitalpattern piece for the left pant leg front. FIG. 31F shows a photographof a right pant leg front of the jeans with the background, and FIG. 31Gshows the extracted neutral digital pattern piece for the right pant legfront.

FIG. 31H shows a photograph of a right pant leg back or rear of thejeans with the background, and FIG. 31I shows the extracted neutraldigital pattern piece for the right pant leg back. FIG. 31J shows aphotograph of a left pant leg back or rear of the jeans with thebackground, and FIG. 31K shows the extracted neutral digital patternpiece for the left pant leg back.

The extracted pattern pieces are shadow neutral since the pattern pieceswere photographed while flat. In contrast, for garments that arephotographed or scanned while on a fit model or mannequin, the extractedpattern pieces would not be shadow neutral. The garment pieces based oncurved surfaces, conforming to the shape of the fit model or mannequin.When the curved surfaces are flattened, there would be shadowing, suchas wrinkles and other aberrations. So when those nonshadow neutralextracted pattern pieces are used with a three-dimensional model togenerate a preview, the preview will have an appearance that does notlook natural, such as having unusual shadowing.

A specific example of create shadow neutral texture pieces 2824 follows.FIG. 32A-32C show the extracted shadow neutral pattern pieces. FIG. 32Dshows a shadow neutral texture created using the extracted shadowneutral pattern pieces and a color layer 3202.

To create the shadow neutral texture, the extracted shadow neutralpattern pieces are combined with a color layer, which typically is acolor which is close to that of a color the garment. For example, forblue jeans, the color layer used will be a similar shade of blue orindigo as on the blue jeans.

The color layer of the shadow neutral texture allows stitching togetherof the different neutral pattern pieces, when mapped to athree-dimensional model, such any potential gaps between the patternpieces will appear seamless. For example, if a very different color isused for the color layer, such as white, than the jeans color, then gapsthat do not exactly align may show this color (e.g., white line).

A specific example of map shadow neutral texture to three-dimensional(3D) model 2830 follows. FIG. 33A shows a created shadow neutral texture3307. FIG. 33B shows a front view of a three-dimensional model, whichthe shadow neutral texture will be applied or mapped to. FIG. 33C showsa result of mapping the shadow neutral texture to the three-dimensionalmodel. This figure shows the front of the garment with the form andwrinkles (e.g., subtle draping, subtle pleating, and other surfacecontouring) resulting from the mapping to the three-dimensional model.The mapping will show the garment to have an appearance of when thegarment is worn by a person. This image can be used as athree-dimensional preview image.

In an implementation, a digital design tool generates athree-dimensional photorealistic visualization garment with a selectedfinishing pattern). The garment will appear as though it is worn by aperson, with simulated wrinkling or simulated shadowing, or both. Theappearance of a worn garment is in contrast to a flat garment, such aswhen a garment is lying on a table or shelf (which is generally atwo-dimensional image). Additionally, when the wear pattern (which is inthe laser file as a two-dimensional image) is mapped onto the garment,the wear pattern is transformed, converted, or mapped (such as by usingmathematical calculations) to have a three-dimensional appearance,similar to situation of how the garment pieces are mapped thethree-dimensional model.

The digital design tool allows various and combinations of manipulationsof the three-dimensional photorealistic visualization. For example, inan implementation, the user can reposition the light source as desired,which will change the appearance of the shadowing. For example, thelight source can be from the front, back, left side, right side, above,below, or other positioning.

In an implementation, the user can change the rotation angle (or angularpoint of view) through which the garment is viewed. For example, theuser can rotate the garment 360 degrees in the X direction (e.g., leftand right). The user can rotate the garment 360 degrees in the Ydirection (e.g., left and right). And the user can rotate the garment.And the user can rotate the garment in any angle in a combination of Xand Y directions. At any angle of rotation, the garment can be zoomed inor zoomed out. When zoomed in, the user can see, for example, the finedetails of the material or wear pattern. When zoomed out, the user cansee, for example, the entire garment from various perspectives.

In an implementation, the user can change a positioning of the garmentitself. For example, the user can reposition the garment to a left-handside position. The user can reposition the garment to a right-hand sideposition. The user can reposition the garment to a further backposition. The user can reposition the garment to a further forwardposition.

Similarly, FIG. 33D shows a back or rear view of the three-dimensionalmodel, which the shadow neutral texture will be applied or mapped to.FIG. 33E shows a result of mapping the shadow neutral texture to thethree-dimensional model. This figure shows the back of the garment withthe form and wrinkles resulting from the mapping to thethree-dimensional model. This image can be used as a three-dimensionalpreview image.

There are various ways to generate a three-dimensional model. Onetechnique is to generate a three-dimensional model from a scan of aphysical three-dimensional object, such as a fit model or mannequin.Another technique to create a three-dimensional model from scratch usingsoftware. Such software can allow a designer to three-dimensional modelanalogous to using molding a clay sculpture. Another technique to createa three-dimensional model from software (e.g., computer aided design(CAD) or computer aided manufacturing (CAM) tool) where two-dimensionalpattern pieces of a garment are converted into to three dimensions.

A specific example of apply simulated light or shadowing, or both, 2836follows. A shadow neutral texture and three-dimensional model can beinputs to a rendering engine or software to render the preview image.Some examples of rendering engines include Google's ARCore, WebGL, andothers. U.S. patent application 62/877,830, filed Jul. 23, 2019,describes further details of three-dimensional rendering oflaser-finished garments and is incorporated by reference.

With the rendering engine, an object such as the garment can be renderedor previewed with shadowing generated by the engine or software. Theshadows will change based on a relative positioning of a simulated lightsource and object. Further, the rendering engine can change a cameraposition of point of view (POV) of the user, so that the preview willhave the shadowing from that camera position.

In a specific implementation, a rendering engine maps the shadow neutraltexture to the three-dimensional model, or preview image, and generatesthe preview image with shadowing based on a positioning of a simulatedlight source. The positioning of the light source can be changed orvaried.

For example, FIG. 34A shows an example of a simulated light sourcepositioned to a right of and above the garment. FIG. 34B shows anexample of a simulated light source positioned directly above (e.g.,centered) the garment. FIG. 34C shows an example of a simulated lightsource positioned to a left of and above the garment. The shadowing,wrinkles, and contours are shown in the preview image in accordance withpositioning the simulated light source. The shadows are generated by therendering software. This is in contrast to shadows that are presentgarment when the photographs or scans are taken, when a shadow neutraltexture creation approach is not user.

Alternatively, the user can rotate or change the positioning of thegarment, and the shadowing, wrinkles, and contours will be shown inaccordance with the changed positioning. This is due to the change inthe relative positioning between the garment and the light source. Theshadows are generated by the rendering software.

FIG. 35A shows an example of a first shadow neutral texture, which is apair of jeans having a finish of a first shade. FIG. 35B shows anexample of a second shadow neutral texture, which is a pair of jeanshaving a finish of a second shade. The second shade is different andlighter than the first shade. FIG. 35C shows various view of athree-dimensional model. There are front, back, left side, and rightside views.

FIG. 35D shows of the first shadow neutral texture mapped to thethree-dimensional model to generate a corresponding preview image. Thefigure shows various view of the preview image. FIG. 35E shows of thesecond shadow neutral texture mapped to the three-dimensional model togenerate a corresponding preview image. The figure shows various view ofthe preview image.

FIGS. 35A-35E show how a single three-dimensional model can be used withmultiple shadow neutral texture to generate a multiple preview images.This allows one three-dimensional model to be used with multiple shadowneutral textures to more easily and rapidly generate preview images withdifferent finishes.

Furthermore, there can be multiple three-dimensional models, such as afirst three-dimensional model and a second three-dimensional model. Thedifferent three-dimensional models may represent different fits orstyles. Then a single shadow neutral texture can be mapped to the firstthree-dimensional model to generate a corresponding preview image. Andthe single shadow neutral texture can be mapped to the secondthree-dimensional model to generate a corresponding preview image.

This allows generating multiple previews from a single shadow neutraltexture. For example, a first preview may be for a first fit or style inthe finish of the shadow neutral texture. And a second preview may befor a second fit or style in the same finish. This technique allows formore a single shadow neutral texture to be used to more easily andrapidly generate preview images of different models, where models canrepresent different fits (e.g., Levi's 501, 502, 504, 505, 511, 512,514, 541, 311, 710, or 711) or styles (e.g., skinny, boot cut, wide leg,straight, relaxed, super skinny, slim, tapered, athletic, boyfriend,wedgie, and others).

This description of the invention has been presented for the purposes ofillustration and description. It is not intended to be exhaustive or tolimit the invention to the precise form described, and manymodifications and variations are possible in light of the teachingabove. The embodiments were chosen and described in order to bestexplain the principles of the invention and its practical applications.This description will enable others skilled in the art to best utilizeand practice the invention in various embodiments and with variousmodifications as are suited to a particular use. The scope of theinvention is defined by the following claims.

The invention claimed is:
 1. A method comprising: providing a garmentpreviewing tool that allows previewing on a computer screen of a jeansgarment customized by the user with a finishing pattern created using alaser input file by a laser, wherein a preview image generated by thegarment previewing tool is a three-dimensional preview image of thejeans garment after a postlaser wash, simulated to have an appearancewhen worn by a person, and is rotatable in three dimensions to be viewedfrom an angle selected by the user, and the garment previewing toolcomprises providing an option for the user to select a jeans garmentbase and upon the user's selection, showing a first garment previewimage on the computer screen comprising a jeans base image for theselected garment base, providing an option for the user to select a wearpattern from a menu of wear patterns, wherein each wear pattern isassociated with a laser input file to be used by a laser to produce thatwear pattern onto a jeans garment, after the wear pattern is selected,showing a second garment preview image on the computer screen comprisingthe selected wear pattern in combination with the jeans base image,wherein the second garment preview image replaces the first garmentpreview image, in the second garment preview image, allowing the user toselect the wear pattern and modify a sizing of the wear pattern relativeto the jeans base image, wherein as the user makes changes, the modifiedsizing of the wear pattern is displayed to the user in real time, in thesecond garment preview image, allowing the user to select the wearpattern and modify a position of the wear pattern relative to the jeansbase image, wherein as the user makes changes, the modified positioningof the wear pattern is displayed to the user in real time, and showing athird garment preview image on the computer screen comprising the jeansbase image and selected wear pattern, with modified sizing or modifiedpositioning, or a combination; providing a target pair of jeanscorresponding to the jeans garment base selected by the user; and basedon laser input file associated with the third garment preview imagecomprising the selected wear pattern with modified sizing or modifiedpositioning, or a combination, using a laser to create a finishingpattern on an outer surface of the target jeans.
 2. The method of claim1 wherein a method of manufacturing the target pair of jeans comprises:assembling the target jeans from fabric panels of a woven first materialcomprising a warp comprising indigo ring-dyed cotton yarn, wherein thefabric panels are sewn together using thread.
 3. The method of claim 2wherein based on the laser input file, the laser removes selectedamounts of material from the surface of a material of the target jeansat different pixel locations of the garment, and for lighter pixellocations of the finishing pattern, a greater amount of the indigoring-dyed cotton warp yarn is removed, while for darker pixel locationsof the finishing pattern, a lesser amount of the indigo ring-dyed cottonwarp yarn is removed
 4. A method comprising: providing a garmentpreviewing tool that allows previewing on a computer screen of a garmentcustomized by the user with a finishing pattern created using a laserinput file by a laser, wherein a preview image generated by the garmentpreviewing tool is a three-dimensional preview image of the jeansgarment after a postlaser wash, simulated to have an appearance whenworn by a person, and is rotatable in three dimensions to be viewed froman angle selected by the user, and the garment previewing tool comprisesproviding an option for the user to select a garment base and upon theuser's selection, showing a first garment preview image on the computerscreen comprising a base image for the selected garment base, providingan option for the user to select a pattern from a menu of patterns,wherein each pattern is associated with a laser input file, after thepattern is selected, showing a second garment preview image on thecomputer screen comprising the selected pattern in combination with thebase image, wherein the second garment preview image replaces the firstgarment preview image, in the second garment preview image, allowing theuser to select the pattern and alter a sizing of the pattern relative tothe base image, wherein as the user makes changes, the altered sizing ofthe pattern is displayed to the user in real time, in the second garmentpreview image, allowing the user to select the pattern and alter aposition of the pattern relative to the base image, wherein as the usermakes changes, the altered positioning of the pattern is displayed tothe user in real time, and showing a third garment preview image on thecomputer screen comprising the base image and selected pattern, withaltered sizing or altered positioning, or a combination.
 5. The methodof claim 4 comprising: based on the third garment preview imagecomprising the selected pattern with altered sizing or alteredpositioning, or a combination, using a laser to create a finishingpattern on an outer surface of a garment that is represented by thirdgarment preview image.
 6. The method of claim 5 wherein based on thelaser input file associated with the pattern used in the third garmentpreview image, the laser removes selected amounts of material from thesurface of the first material at different pixel locations of thegarment, and for lighter pixel locations of the finishing pattern, agreater amount of the dyed cotton warp yarn is removed, while for darkerpixel locations of the finishing pattern, a lesser amount of the dyedcotton warp yarn is removed.
 7. The method of claim 5 wherein afinishing pattern based on the third garment preview image can extendacross portions of the garment where two or more fabric panels arejoined together by thread by exposing these portions to the laser. 8.The method of claim 5 wherein for portions of the garment exposed to thelaser where the fabric panels are joined, the fabric panels are joinedtogether using a thread comprising cotton.
 9. The method of claim 5wherein when using the laser to create a finishing pattern, differentlaser levels are obtained by varying an output of the laser beam byaltering a characteristic of the laser comprising at least one of afrequency, period, pulse width, power, duty cycle, or burning speed. 10.The method of claim 4 wherein the garment comprises at least one of adenim garment, pair of pants, pair of jeans, or a pair of denim jeans.11. The method of claim 4 wherein the garment is made of at least on ofa twill material or a cotton twill material.
 12. The method of claim 4wherein the user can alter the sizing of the pattern relative to thebase image by way of an operation comprising at least one of rotatingthe pattern relative to the base image, stretching one or moredimensions of the base image relative to the base image, shrinking oneor more dimensions of the base image relative to the base image,enlarging the pattern relative to the base image, or compressing thepattern relative to the base image.
 13. The method of claim 4 whereinthe pattern comprises an inverse image of a laser input file.
 14. Themethod of claim 4 comprising: providing an option for the user to selecta tint from a menu of tints; and after the tint is selected, showing afourth garment preview image on the computer screen comprising the tintin combination with the base image and selected pattern, with alteredsizing or altered positioning, or a combination.
 15. The method of claim4 comprising: providing an option for the user to select a damage from amenu of damages; and after the damage is selected, showing a fourthgarment preview image on the computer screen comprising the damage incombination with the base image and selected pattern, with alteredsizing or altered positioning, or a combination; in the fourth garmentpreview image, allowing the user to select the damage and alter a sizingof the damage relative to the base image and selected pattern, whereinas the user makes changes, the altered sizing of the damage is displayedto the user in real time; in the fourth garment preview image, allowingthe user to select the damage and alter a position of the damagerelative to the base image and selected pattern, wherein as the usermakes changes, the altered positioning of the damage is displayed to theuser in real time; and showing a fifth garment preview image on thecomputer screen comprising the base image, selected pattern, withaltered sizing or altered positioning, or a combination, and the damage,with altered sizing or altered positioning, or a combination.
 16. Themethod of claim 15 wherein the user can alter the sizing of the damagerelative to the base image and selected pattern by way of an operationcomprising at least one of rotating the damage relative to the baseimage and selected pattern, stretching one or more dimensions of thedamage relative to the base image and selected pattern, shrinking one ormore dimensions of the damage relative to the base image and selectedpattern, enlarging the damage relative to the base image and selectedpattern, or compressing the damage relative to the base image andselected pattern.
 17. The method of claim 4 comprising: providing anoption for the user to alter a brightness parameter that adjusts anopacity of the selected pattern relative to the base image; and via aslider bar interface, allowing the user to modify the brightnessparameter and showing to the user in real time an effect of changes inthe brightness parameter in a fourth preview image.
 18. The method ofclaim 4 comprising: providing an option for the user to alter a brightpoint parameter that adjusts a midpoint of a grayscale used to create apiecewise linear mapping of the selected pattern; and via a slider barinterface, allowing the user to modify the bright point parameter andshowing to the user in real time an effect of changes in the brightnessparameter in a fourth preview image.